Variable Speed AC Motor Drives AC400 Series Installation and Operation Manual
TABLE OF CONTENTS 1.0 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 2.0 AC400 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 3.0 AC400 MODEL DESIGNATION CODE . . . . . . . . . . . . . . . . . . . . . . .5 4.0 AC400 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 5.0 AC400 RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 6.
1.0 GENERAL 1.1 PRODUCTS COVERED IN THIS MANUAL This manual covers the Minarik AC400 Series Variable Frequency Drive. 1.2 PRODUCT CHANGES Minarik Corporation reserves the right to discontinue or make modifications to the design of its products without prior notice, and holds no obligation to make modifications to products sold previously. Minarik Corporation also holds no liability for losses of any kind which may result from this action. 1.
1.5 CUSTOMER MODIFICATION Minarik Corporation, its sales representatives and distributors, welcome the opportunity to assist our customers in applying our products. Many customizing options are available to aid in this function. Minarik Corporation cannot assume responsibility for any modifications not authorized by its engineering department.
2.0 AC400 SPECIFICATIONS Storage Temperature -20° to 70° C Ambient Operating Temperature (With 2.
3.0 AC400 MODEL DESIGNATION CODE The model number of an AC400 Series drive gives a full description of the basic drive unit (see example below). EXAMPLE: AC424T-3.
4.0 AC400 DIMENSIONS 4.1 CHASSIS AND TYPE 1 ENCLOSED HP INPUT VOLTAGE MODEL H W D N P Q R S 0.25 240 / 120 AC421S-0.2 7.50 4.70 3.33 2.35 1.60 1.37 5.50 0.88 0.5 240 / 120 240 240 / 200 AC421S-0.4 AC422S-0.4 AC422T-0.4 7.50 7.50 7.50 6.12 4.70 4.70 3.63 3.63 3.63 3.77 2.35 2.35 1.80 1.90 1.90 1.37 1.37 1.37 5.50 5.50 5.50 0.88 0.88 0.88 1 240 / 120 240 240 / 200 480 / 400 590 AC421S-0.75 AC422S-0.75 AC422T-0.75 AC424T-0.75 AC425T-0.75 7.50 7.50 7.50 7.50 7.50 6.12 4.
DIMENSIONS - CHASSIS AND TYPE 1 ENCLOSED (continued) INPUT VOLTAGE MODEL H W D N P Q R S 5 240 / 200 480 / 400 590 AC422T-3.7 AC424T-3.7 AC465T-3.7 7.88 7.50 7.88 7.86 6.12 7.86 5.94 5.12 5.94 5.13 3.77 5.13 3.95 3.30 3.95 1.50 1.37 1.50 5.88 5.50 5.58 1.13 0.88 1.13 7.5 240 / 200 480 / 400 590 AC422T-5.5 AC424T-5.5 AC425T-5.5 9.38 9.38 9.38 7.86 7.86 7.86 6.84 6.25 6.25 3.93 5.13 5.13 4.19 3.95 3.95 2.00 1.50 1.50 5.88 7.38 7.38 1.13 1.13 1.
4.2 TYPE 4, 4X, AND 12 ENCLOSED HP INPUT VOLTAGE MODEL H W D N P Q R S 0.25 240 / 120 AC4x1S-0.2 7.88 6.12 3.63 3.06 2.00 1.37 5.88 0.88 0.5 240 / 120 240 240 / 200 AC4x1S-0.4 AC4x2S-0.4 AC4x1T-0.4 7.88 7.88 7.88 7.86 6.12 6.12 3.75 4.35 4.35 4.80 3.06 3.06 2.10 2.70 2.70 1.37 1.37 1.37 5.88 5.88 5.88 0.88 0.88 0.88 1 240 / 120 240 240 / 200 480 / 400 590 AC4x1S-0.75 AC4x2S-0.75 AC4x2T-0.75 AC4x4T-0.75 AC4x5T-0.75 7.88 7.88 7.88 7.88 7.88 7.86 6.12 6.12 6.12 6.12 4.
DIMENSIONS - TYPE 4, 4X, AND 12 ENCLOSED (continued) INPUT VOLTAGE MODEL H W D N P Q R S 3 240 240 / 200 480 / 400 590 AC4x2S-2.2 AC4x2T-2.2 AC4x4T-2.2 AC4x5T-2.2 7.88 7.88 7.88 7.88 7.86 7.86 7.86 7.86 5.9 5.9 4.9 4.9 4.8 4.8 4.8 4.8 4.25 4.25 3.25 3.25 1.37 1.37 1.37 1.37 5.88 5.88 5.88 5.88 0.88 0.88 0.88 0.88 5 240 / 200 480 / 400 590 AC4x2T-3.7 AC4x4T-3.7 AC4x5T-3.7 9.75 7.88 7.88 10.26 7.86 7.86 7.20 5.90 5.90 5.13 4.80 4.80 5.25 4.25 4.25 2.00 1.37 1.37 7.75 5.88 5.
5.0 AC400 RATINGS The following tables indicate the input and output ratings of the AC400 Series drive. NOTE: The output current ratings are based no operation at carrier frequencies of 8 kHz and below. At full ambient temperature, operation at carrier frequencies above 8 kHz require derating the drive by multiplying the output current rating by the following factors: 0.94 at 10 kHz, 0.89 at 12 kHz, and 0.83 at 14 kHz. Refer to Parameter 23 (CARRIER) in Section 18.0 (DESCRIPTION OF PARAMETERS).
AC4x2 SERIES RATINGS MODEL INPUT (240 VAC, 50 - 60 Hz) OUTPUT (0 - 230 VAC) MODEL NUMBER (NOTE 1) RATED HP INPUT PHASE NOMINAL CURRENT (AMPS) (NOTE 2) POWER (KVA) NOMINAL CURRENT (AMPS) (NOTE 2) POWER (KVA) AC4x2S-0.4 1/2 1 5.0 1.2 2.2 0.9 AC4x2T-0.4 1/2 3 2.7 1.1 2.2 0.9 AC4x2S-0.75 1 1 9.0 2.2 4.0 1.6 AC4x2T-0.75 1 3 4.8 2.0 4.0 1.6 AC4x2S-1.1 1.5 1 11.6 2.8 5.2 2.1 AC4x2T-1.1 1.5 3 6.2 2.6 5.2 2.1 AC4x2S-1.5 2 1 14.9 3.6 6.8 2.7 AC4x2T-1.
AC4x4 SERIES RATINGS MODEL INPUT (480 Vac, 50 - 60 Hz) OUTPUT (0 - 460 Vac) MODEL NUMBER (NOTE 1) RATED HP INPUT PHASE NOMINAL CURRENT (AMPS) (NOTE 2) POWER (KVA) NOMINAL CURRENT (AMPS) (NOTE 2) POWER (KVA) AC4x4T-0.75 1 3 2.4 2.0 2.0 1.6 AC4x4T-1.5 2 3 4.1 3.4 3.4 2.7 AC4x4T-2.2 3 3 5.7 4.7 4.8 3.8 AC4x4T-3.7 5 3 8.9 7.3 7.6 6.1 AC4x4T-5.5 7.5 3 12.8 10.6 11.0 8.8 AC4x4T-7.5 10 3 15.9 13.2 14.0 11.2 AC4x4T-11 15 3 23.8 19.8 21.0 16.
AC4x5 SERIES RATINGS MODEL INPUT (590 VAC, 50 - 60 Hz) OUTPUT (0 - 575 VAC) MODEL NUMBER (NOTE 1) RATED HP INPUT PHASE NOMINAL CURRENT (AMPS) (NOTE 2) POWER (KVA) NOMINAL CURRENT (AMPS) (NOTE 2) POWER (KVA) AC4x5T-0.75 1 3 1.9 1.9 1.6 1.6 AC4x5T-1.5 2 3 3.3 3.4 2.7 2.7 AC4x5T-2.2 3 3 4.6 4.7 3.9 3.9 AC4x5T-3.7 5 3 7.1 7.3 6.1 6.1 AC4x5T-5.5 7.5 3 10.5 10.7 9.0 8.8 AC4x5T-7.5 10 3 12.5 12.8 11.0 11.0 AC4x5T-11 15 3 19.3 19.7 17.0 16.9 21.
6.0 THEORY 6.1 DESCRIPTION OF AC MOTOR OPERATION Three phase AC motors are comprised of two major components, the stator and the rotor. The stator is a set of three electrical windings held stationary in the motor housing. The rotor is a metal cylinder, fixed to the motor drive shaft, which rotates within the stator. The arrangement of the stator coils and the presence of three phase AC voltage give rise to a rotating magnetic field which drives the rotor.
If the frequency applied to the motor is increased while the voltage remains constant, torque capability will decrease as speed increases. This will cause the horsepower capability of the motor to remain approximately constant. Motors run in this mode when operated above base speed, where drive output voltage is limited by the input line voltage. This operating range is known as the “constant horsepower” range. The typical maximum range for constant horsepower is about 2.3 to 1 (60 to 140 Hz).
“Variable torque” refers to the fact that the torque required varies with the square of the speed. Also, the horsepower required varies with the cube of the speed, resulting in a large reduction in horsepower for even a small reduction in speed. It is easily seen that substantial energy savings can be achieved by reducing the speed of a fan or pump. For example, reducing the speed to 50% results in a 50 HP motor having to produce only 12.5% of rated horsepower, or 6.25 HP.
6.2.2 CIRCUIT DESCRIPTION The control section consists of a control board with a 16 bit microprocessor, keypad and display. Drive programming is accomplished via the keypad or the serial communications port. During operation the drive can be controlled via the keypad, by control devices wired to the control terminal strip, or by the the serial communications port. The Power Board contains the control and protection circuits which govern the six output IGBTs.
6.2.5 AC400 STATUS OUTPUT RELAYS The control board has one Form C relay at terminals TB-16, TB-17, and TB-18. Contacts are rated for 2 amps at 28 VDC or 120 Vac. There are also two open-collector outputs at terminals TB-14 and TB-15. The open-collector circuit is a current sinking type rated at 30 VDC and 40 mA maximum. An external power supply (30 VDC max.) must be used to power the open-collector outputs. The drive does not have a dedicated power supply for the open-collector outputs.
@ SPEED AT SPEED - The relay energizes when the drive reaches the speed setpoint. To avoid a “chattering” relay (energizing and de-energizing), due to small fluctuations in speed, the relay will remain energized as long as the actual speed is within + 3 Hz of the speed setpoint. ABOVE #3 ABOVE SPEED #3 - The relay energizes when the output frequency exceeds the SPEED #3 value, and de-energizes when the output frequency returns to a value lower than the SPEED #3 value.
7.0 INSTALLATION Warning Drives must not be installed where subjected to adverse environmental conditions! Drives must not be installed where subjected to: combustible, oily, or hazardous vapors or dust; excessive moisture or dirt; strong vibration; excessive ambient temperatures. Consult Minarik for more information on the suitability of a drive to a particular environment. The drive should be mounted on a smooth vertical surface capable of safely supporting the unit without vibrating.
7.1 INSTALLATION AFTER A LONG PERIOD OF STORAGE Warning Severe damage to the drive can result if operated after long periods of storage or inactivity without reforming the DC bus capacitors! If input power has not been applied to the drive for a period of time exceeding three years (due to storage, etc), the electrolytic DC bus capacitors within the drive can change internally, resulting in excessive leakage current.
8.0 INPUT AC REQUIREMENTS Warning Hazard of electrical shock! Disconnect incoming power and wait three minutes before servicing the drive. Capacitors retain charge after power is removed. 8.1 INPUT AC POWER REQUIREMENTS 8.1.1 VOLTAGE: The input voltage must match the drive’s nameplate voltage rating. Voltage fluctuation must not vary by greater than 10% overvoltage or 15% undervoltage.
Minimum voltage rating of the protection device should be 250 Vac for 240/120 Vac and 240/200 Vac rated drives, and 600 Vac for 480/400 Vac and 590/480 Vac drives. Current limiting type fuses should be used when input fusing is required. Select fuses with low I 2 T values, rated at 200,000 AIC. Recommended fuses are Bussman type KTK-R. Similar fuses with equivalent ratings by other manufacturers may also be acceptable. 9.0 VOLTAGE SELECTION 9.
10.0 POWER WIRING Warning Hazard of electrical shock! Disconnect incoming power and wait three minutes before servicing the drive. Capacitors retain charge after power is removed. Note drive input and output current ratings and check applicable electrical codes for required wire type and size, grounding requirements, overcurrent protection, and incoming power disconnect, before wiring the drive. Size conservatively to minimize voltage drop.
11.0 AC400 POWER WIRING DIAGRAM Warning Do not connect incoming AC power to output terminals T1, T2, or T3. This will result in severe damage. INSTALL, WIRE, AND GROUND IN ACCORDANCE WITH ALL APPLICABLE CODES. NOTES: 1. Wire the motor for the proper voltage per the output rating of the drive. Motor wires MUST be run in a separate steel conduit away from control wiring and incoming AC power wiring. 2.
12.0 INITIAL POWER UP Warning Hazard of electrical shock! Wait three minutes after disconnecting incoming power before servicing the drive. Capacitors retain charge after power is removed. Before attempting to operate the drive, motor, and driven equipment be sure all procedures pertaining to installation and wiring have been properly followed.
If the display does not appear, remove the incoming power, wait three minutes for the bus capacitors to discharge, and verify correct installation and wiring. If the wiring is correct, reapply incoming power and note the display for drive status. If the display still does not appear call the factory for assistance. If the drive powers up correctly, follow the procedure given below to check the motor rotation: 1. Verify that there is a wire jumper between terminals TB-1 and TB-2 on the Main Control Board.
13.0 KEYPAD CONTROL The drive can be operated in a number of different ways: keypad (LOCAL), control devices wired to the terminal strip (REMOTE), serial communications (SERIAL), or combinations of each. The drive should first be operated from the keypad during initial start-up. Refer to Sections 14.0 - CONTROL WIRING, and 18.0 - DESCRIPTION OF PARAMETERS for information on remote operation. 13.1 KEYPAD FUNCTIONS START/STOP To start the drive, press the START key.
FAULT RESET Use the STOP key to reset a fault. If the fault condition has passed, pressing the STOP key will clear the fault and return the drive to a STOP condition. NOTE: If an OUTPUT fault occurs, there will be a 30 second delay before the fault can be cleared using the STOP key. 13.2 AC400 DISPLAY The following describes the possible display configurations for the AC400 Series drive when operating as a standard drive (without PID control). Refer to Section 19.
The following table shows the possible DRIVE STATUS indications that can appear on the drive display: DRIVE STATUS TABLE DISPLAY DESCRIPTION STOP Drive is in STOP mode - No output to the motor. RUN Drive is in RUN mode and is within ± 3 Hz of the speed setpoint. FAULT Drive has shut down due to a FAULT condition. If the fault condition has passed, pressing the STOP key will clear the fault and return the drive to the STOP mode.
13.2.2 AC400 DISPLAY IN RUN MODE When the drive is in the RUN mode, the default display will look like this: As in the STOP mode, the ENTER key can be used to toggle the display from SPEED to % LOAD to VAC (motor voltage): NOTE: During acceleration and deceleration to the SPEED SETPOINT, the DRIVE STATUS will show the actual drive speed. When the SPEED SETPOINT is reached, the DRIVE STATUS will change to RUN (or STOP if the drive is decelerating to a STOP).
13.2.3 AC400 DISPLAY IN FAULT MODE When the drive trips on a fault, the display will automatically change to the FAULT display, which indicates the FAULT MESSAGE: In FAULT mode, the ENTER key will toggle the display between four screens: FAULT, SPEED, % LOAD and VAC. The DRIVE STATUS for these displays will be FAULT. An example is shown below of the drive in the FAULT mode displaying SPEED.
The table below shows the possible SPEED REFERENCE SOURCE indications for the CONTROL display in the auxiliary mode: SPEED REFERENCE SOURCE TABLE DISPLAY DESCRIPTION KEY KEYPAD - UP and DOWN arrow keys. VDC 0 - 10 VDC analog input at TB-5A (In PID mode, this indicates that the SETPOINT reference is a 0-10 VDC signal). IDC 4 - 20 mA analog input at TB-5B (In PID mode, this indicates that the SETPOINT reference is a 4-20 mA signal).
14.0 CONTROL WIRING 14.1 GENERAL 14.1.1 KEYPAD CONTROL The drive can be controlled by the keypad or by control devices wired to the terminal strip. The drive will run from the keypad “out of the box”, as long as the factory jumper between TB-1 and TB-2 is present, as shown below. If the jumper is not present, add one, otherwise the drive will not start from the keypad. Refer to Section 13.0 (KEYPAD CONTROL). 14.1.2 CONTROL WIRING VS.
14.2 START/STOP AND SPEED CONTROL 14.2.1 REMOTE MODE SELECTION In order to respond to external START/STOP commands, the drive must be in the REMOTE mode. The REMOTE mode can be selected by one of three methods on the AC400 drive: 1. Program Parameter 30 - CONTROL to REMOTE. 2. Program Parameter 30 - CONTROL to KEYPAD or KEYPAD 2, which activates the LOCAL/REMOTE key on the keypad. Press the LOCAL/REMOTE key to select REMOTE mode, and then press the ENTER key within three seconds. 3.
14.2.4 SPEED REFERENCE SIGNALS The drive allows for three analog speed reference inputs: a speed potentiometer (10,000 Ohm), 0-10 VDC, or 4-20 mA. SPEED POT Connect the wiper to terminal TB-5A, and connect the high and low end leads to terminals TB-6 and TB-2, respectively. 0-10 VDC Wire the positive to terminal TB-5A and the negative to terminal TB2. TB-5A input impedance is 200 kilohms. 4-20 mA Wire the positive to terminal TB-5B and the negative to terminal TB-2. TB-5B input impedance is 100 Ohms.
AUTO/MAN SELECTION IN REMOTE MODE In REMOTE mode (terminal strip start/stop control), speed control is either selected using the AUTO/MAN key (Parameter 28 - AUTO/MAN must be set to A/M SPD to do this), or by using the TB-13 input selects. If AUTOMATIC mode is selected using the AUTO/MAN key (Parameter 28 - AUTO/MAN must be set to A/M SPD to do this), and a speed reference is not selected using one of the TB-13 input selects, the drive will remain in AUTO mode, but speed control will default to the keypad.
14.2.6 ANALOG OUTPUT SIGNALS There are two terminals that can supply analog output signals proportional to output frequency or load. Terminal TB-10A can provide a 0-10 VDC or a 2-10 VDC signal proportional to output frequency, and TB-10B can provide the same signals proportional to load. The 2-10 VDC signals can be converted to a 4-20 mA signal using a resistor in series with the signal such that the total circuit resistance is 500 Ohms.
15.0 AC400 CONTROL WIRING DIAGRAMS 15.1 AC400 TERMINAL STRIP Shown below is the terminal strip on the main control board, along with a brief description of the function of each terminal. Wiring shown above the terminal strip indicates internal wiring on the main control board. NOTE The function of terminals TB-10A, TB-10B, TB-13A, TB-13B, TB-13C, TB-13D, TB-14, TB-15, TB-16, and TB-18 are dependent on the programming of certain parameters.
15.2 TWO-WIRE START/STOP CONTROL Shown below is the wiring diagram for a typical two-wire start/stop control scheme, using one maintained contact (such as that from a PLC) for RUN and STOP commands. Close the contact to RUN, and open the contact to STOP. Also shown is the wiring for a 0-10 VDC or 4-20 mA speed reference signal. NOTES: 1. Close TB-1 to TB-2 to RUN, and open to STOP. 2. Program TB-13A, 13B, or 13C to select the desired speed reference signal.
15.3 THREE-WIRE START/STOP CONTROL Shown below is the wiring diagram for a typical three-wire start/stop control scheme, using momentary contacts (such as pushbuttons) for START and STOP commands. Also shown is the wiring for a 0-10 VDC or 4-20 mA speed reference signal. NOTES: 1. Momentarily close TB-12A to TB-2 to START, and momentarily open TB-1 to TB-2 to STOP. 2. Program TB-13A, 13B, or 13C to select desired speed reference signal.
15.4 SPEED POT AND PRESET SPEED CONTROL Shown below is the wiring diagram for a control scheme that utilizes a speed pot and PRESET SPEEDS for speed control, and either a two-wire or three-wire START/STOP circuit: NOTES: 1. Program the preset speeds to the desired values (see Parameters 1-4: SPEED #1 - #4). 2. Program TB-13A to select SPEED #1, TB-13B to select SPEED #2, and TB-13C to select SPEED #3 (see Parameters 47, 48 and 49). 3.
16.0 PROGRAMMING THE AC400 DRIVE 16.1 PROGRAMMING THE PARAMETERS The AC400 keypad serves two purposes: operating the drive when in the LOCAL mode, and programming the parameters for particular applications. The keypad is shown below, along with the display that should appear when the drive is first powered up: To program the drive, the PROGRAM mode must be entered by pressing the PROG/RUN button.
Once the correct password is entered, the PROGRAM mode will be entered and the first parameter will be displayed, which is Parameter 0 - LINE VOLTS. This is shown below: To scroll through the parameters, use the UP and DOWN arrow buttons on the keypad. When the desired parameter is found, press the ENTER key to shift the cursor from the parameter name to the parameter value.
16.2 PARAMETER ACCESS USING SPEED DIAL SPEED DIAL is used to access parameters quickly using the parameter number. Once accessed, the parameter can be programmed as described in Section 16.1. SPEED DIAL is accessed by pressing the AUTO/MAN key while in the PROGRAM mode. This will activate the SPEED DIAL display as shown below: Once in SPEED DIAL, the UP and DOWN arrow keys will allow the operator to scroll through the parameter numbers.
17.0 PARAMETER MENU PARAMETER MENU PARAM. NUMBER PARAMETER NAME RANGE OF ADJUSTMENT FACTORY DEFAULT 0 LINE VOLTS HIGH, LOW, AUTO AUTO 1 SPEED #1 MIN FRQ - MAX FRQ 20.00 Hz 2 SPEED #2 MIN FRQ - MAX FRQ 20.00 Hz 3 SPEED #3 MIN FRQ - MAX FRQ 20.00 Hz 4 SPEED #4 MIN FRQ - MAX FRQ 20.00 Hz 5 SKIP #1 .00 Hz - MAX FRQ .00 Hz 6 SKIP #2 .00 Hz - MAX FRQ .00 Hz 7 BAND WID .00 - 10.00 Hz 1.00 Hz 8 ACCEL (NOTE 1) 30.0 SEC 9 DECEL (NOTE 1) 30.0 SEC 10 MIN FRQ .
PARAMETER MENU PARAM. NUMBER PARAMETER NAME RANGE OF ADJUSTMENT FACTORY DEFAULT 17 18 19 22 MOTOR OL BASE FX BOOST TORQUE 100% 60.00 Hz (NOTE 1) CONSTANT 23 25 CARRIER START 26 28 STOP AUTO/MAN 30 CONTROL 31 UNITS 25 - 100 % 20.00 - 360.0 Hz .0 - 30.0 % CONSTANT, VARIABLE, CT / NOCMP 2.
PARAMETER MENU PARAM. NUMBER 35 39 40 42 43 44 45 47 PARAMETER NAME CONTRAST TB5 MIN TB5 MAX TB10A OUT @TB10A TB10B OUT @TB10B TB13A 48 TB13B 49 TB13C 50 TB13D 52 53 54 TB14 OUT TB15 OUT RELAY 55 57 TB5B LOSS SERIAL 58 ADDRESS RANGE OF FACTORY ADJUSTMENT DEFAULT LOW, MED, HIGH HIGH .00 - 360.0 Hz .00 Hz .00 - 360.0 Hz 60.00 Hz NONE, 0-10V, 2-10V NONE 3.00 - 360.0 Hz 60.
PARAMETER MENU PARAM. NUMBER 61 63 64 65 66 70 74 75 76 77 78 79 80 81 82 98 99 PARAMETER NAME PASSWORD SOFTWARE MONITOR PROGRAM RANGE OF ADJUSTMENT 0000 - 9999 (VIEW - ONLY) OFF, ON MAINTAIN, RESET 60, RESET 50 HISTORY MAINTAIN, CLEAR PID MODE OFF, NORMAL, REVERSE PID FB TB-5A, TB-5B FB @ MIN 0 - 65000 FB @ MAX 0 - 65000 P GAIN 0.0 - 999.9% I GAIN 0.0 - 10.0 SEC D GAIN 0.0 - 10.0 SEC PID ACC 0.0 - 100.
18.0 0 DESCRIPTION OF PARAMETERS LINE VOLTS (LINE VOLTAGE) This parameter calibrates the drive for the correct input voltage, and can be set to AUTO, HIGH, or LOW. When set to AUTO, the drive measures the DC bus voltage when power is applied and automatically calibrates itself according to the measured value (DC bus voltage is equal to input voltage multiplied by 1.4). This parameter can also be set “manually”, using the HIGH or LOW settings.
The following table shows how each preset speed is selected using the TB-13 terminals. The terms OPEN and CLOSED refer to the state of the TB-13 terminal relative to TB-2.
8 ACCEL (ACCELERATION TIME) ACCEL sets the acceleration rate for all speed reference sources (keypad, speed pot, 4-20 mA, 0-10 VDC, jog, and the preset speeds). The ACCEL setting is the time to accelerate from 0 Hz to the BASE FREQUENCY (Parameter 18). The range of adjustment for ACCEL depends on horsepower. Refer to the table below: ACCELERATION LIMITS HORSEPOWER RANGE OF ADJUSTMENT 0.25 - 20 0.1 - 3600 SEC 25 - 60 0.
NOTE 2: This parameter can be set as low as the value shown in the WITH DB column. However, the value shown in the WITHOUT DB column is the operational limit of a drive without dynamic braking. For example, DECEL can be set as low as 0.1 seconds on a 10 HP, 480 Vac drive without dynamic braking, but the actual minimum deceleration time would be 0.5 seconds. If an attempt is made to decelerate a high-inertia load too quickly, the motor will regenerate voltage back into the drive.
11 MAX FRQ (MAXIMUM FREQUENCY) This parameter defines the upper limit of the drive’s speed range. MAX FRQ is used in conjunction with MIN FRQ (Parameter 10 above) to define the operating range of the drive. Warning Consult motor manufacturer before operating motor above rated frequency. Overspeeding the motor and/or driven equipment can cause damage to equipment and injury to personnel! 12 DC BRAKE (DC BRAKE VOLTAGE) DC braking creates a braking torque by injecting DC voltage into the motor.
13 DC TIME (DC BRAKE TIME) This parameter determines the length of time that the DC braking voltage is applied to the motor. DC TIME should be set to the lowest value that provides satisfactory operation in order to minimize motor heating. Note: If this parameter is set to 999.9 seconds (the maximum value), the DC braking will be continuous. If it is set to 0.9 seconds, it is disabled. 14 DYN BRAK (DYNAMIC BRAKE) This parameter enables the dynamic braking circuit.
17 MOTOR OL (MOTOR OVERLOAD) The AC400 Series is UL approved for solid state motor overload protection. Therefore, a separate thermal overload relay is not required for single motor applications. The MOTOR OVERLOAD circuit is used to protect the motor from overheating due to excessive current draw. The trip time for the MOTOR OVERLOAD setting is based on what is known as an “inverse I2t” function.
Example 2: A 480 Vac, 20 HP drive is operating a motor at 10 Hz. From the diagram, a drive operating at 10 Hz can deliver about 75% of its output current rating continuously. A 480 Vac, 20 HP drive’s output current rating is 27 Amps. Therefore, the drive would be able to operate continuously at 20 Amps. The drive would also be able to deliver 150% of that value (30 Amps) for one minute before tripping into an OVERLOAD fault.
19 FX BOOST (FIXED BOOST) This parameter is used in applications which require high starting torque. FX BOOST increases the output voltage at lower output frequencies (below 30 Hz for 60 Hz base frequency), in order to boost the torque capability of the motor. Refer to the diagram below. The factory default for FX BOOST depends on the horsepower rating of the drive. Refer to the table below: FX BOOST FACTORY DEFAULT SETTINGS HP 0.25 - 1 1.5 - 2 3 5 7.5 10 FACTORY DEFAULT 5.30 4.40 3.60 3.00 2.70 2.
22 TORQUE (TORQUE CURVE SELECTION) This parameter is used to select whether the output of the drive follows a constant or variable V/Hz curve. The following selections are available: CONSTANT Use for constant torque applications to optimize torque. VARIABLE Use for variable torque applications to optimize energy savings. CT / NOCMP Use for constant torque applications that require full overload capacity at low speeds (see Parameter 17 - MOTOR OL).
This parameter selects the starting method for the drive, and can be set for one of the following: NORMAL The drive will start when the appropriate contact closure is made on the terminal strip (REMOTE mode), or by pressing the keypad START key (LOCAL mode). To start the drive in NORMAL mode, a start command must be issued at least two seconds AFTER input power is applied. POWER UP The drive will automatically start upon application of input power.
NOTE 1: When set for AUTO 1, 2, or 3, only the first two restart attempts will perform a speed search to start into a spinning load. The last three restart attempts will apply DC braking (at the voltage level programmed into Parameter 12 - DC BRAKE) for 15 seconds and then start from zero speed. NOTE 2: The drive WILL NOT restart after a CONTROL or PWR SAG fault. Also, if an OUTPUT fault occurs below 1.5 Hz, only one restart will be attempted, after a 30 second delay.
A/M SPD 30 CONTROL The AUTO/MAN key is always active. NOTE: If the drive is switched from LOCAL to REMOTE mode, speed control will switch to AUTO. If the drive is switched from REMOTE to LOCAL mode, speed control will switch to MANUAL mode. The AUTO/MAN key can then be used to select the desired mode. (START/STOP CONTROL) This parameter selects the START/STOP control source, which is either the keypad (LOCAL), the terminal strip (REMOTE), or the serial link (SERIAL).
NOTE 2: Refer to Parameter 70 - PID MODE for information on the effects of LOCAL and REMOTE mode when operating the drive in PID mode. 31 UNITS (SPEED/PID UNITS) This parameter sets the units of the output speed or the PID display on the keypad.
33 UNITS DP (SPEED UNITS DECIMAL POINT) In “non-PID” mode, UNITS DP selects the decimal point location of the speed display. UNITS DP has no effect if UNITS is set to sp HERTZ or sp % HZ. In PID mode, UNITS DP selects the decimal point location for the PID SETPOINT and FEEDBACK displays, and FB @ MIN and FB @ MAX. The possible settings are: XXXXX, XXX.X, XX.XX, X.XXX, and .XXXX. Refer to the above example in Parameter 32 - HZ MULT.
39 TB5 MIN (TERMINAL TB-5 INPUT) This parameter selects the output frequency of the drive that will correspond to the minimum analog speed reference input (0 VDC or 4 mA). This parameter is used in conjunction with Parameter 40 - TB5 MAX to define a speed range for the drive that corresponds to the analog speed reference input (0 - 10 VDC or 4 - 20 mA).
43 @ TB10A (TERMINAL TB-10A SCALING) This parameter scales the analog output signal at TB-10A. This setting is the output frequency that is indicated when the TB-10A output measures 10 VDC. Example: The drive is part of a control system that requires a 0-5 VDC signal (rather than 010 VDC) that is proportional to 0-60 Hz output frequency. The output signal is linear, so setting this parameter to 120 Hz would yield 10 VDC at 120 Hz, and 5 VDC at 60 Hz.
4-20 MA Selects 4-20 mA as the AUTO speed reference input (or setpoint source in PID mode). The 4-20 mA signal is wired to TB-5B and TB-2. SPEED#1 Selects PRESET SPEED #1 as the AUTO speed reference. LOC SEL Selects LOCAL mode when Parameter 30 - CONTROL is set to TB STRIP. Drive is in REMOTE mode if contact closure is not made. DEC FREQ Decrease frequency setpoint. Used with the MOP (motor operated pot) function. Refer to Section 14.2.6 - SPEED REFERENCE SELECTION.
SPEED#3 Selects PRESET SPEED #3 as the AUTO speed reference. LOC SEL LOCAL SELECT - Selects LOCAL mode when Parameter 30 CONTROL is set to TB STRIP. Drive is in REMOTE mode if contact closure is not made. 50 TB13D (TB-13D FUNCTION) Warning EXTERNAL FAULT (TB-13D) circuitry may be disabled if parameters are reset to factory defaults! The drive must be reprogrammed after a RESET in order to insure proper operation (see Parameter 65 - PROGRAM).
The open-collector output circuit is a current-sinking type rated at 30 VDC and 40 mA maximum. An external power supply (30 VDC max.) must be used to power the opencollector outputs. The drive does not have a dedicated power supply for the open-collector outputs. 53 TB15 OUT (TB-15 OPEN COLLECTOR OUTPUT) This parameter sets the open-collector output indication for terminal TB-15. It has the same functionality as Parameter 52 - TB14 OUT above.
DISABLE Serial communication function is disabled. W / TIMER Enables serial communications with a watchdog timer. If there is no serial activity (read or write) for more than 10 seconds, serial control will turn off and the drive will stop. W / O TIMR Enables serial communications without a watchdog timer. However, after 10 seconds of no serial activity, serial control can be turned off by issuing a STOP command from any source (keypad, terminal strip) other than the serial link.
If the ENTER key is pressed while PASSWORD reads 0000, the MONITOR MODE will be entered (if Parameter 64 - MONITOR, is set to ON), which will allow the parameters to be viewed (except for PASSWORD), but not changed. MONITOR MODE is not present in units that have the Metasysâ software option. NOTE 1: The factory default value is 0019. NOTE 2: If PASSWORD is set to 0000, the function is disabled. Pressing the PROG/RUN key will result in direct entry into the PROGRAM mode without having to enter a password.
65 PROGRAM (PROGRAM FACTORY DEFAULTS) Warning EXTERNAL FAULT (TB-13D) circuitry may be disabled if parameters are reset to factory defaults! The drive must be reprogrammed after a RESET in order to insure proper operation (see Parameter 65 - PROGRAM). FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT AND/OR INJURY TO PERSONNEL! This parameter is used to reset the programmable parameters back to the factory default settings.
NORMAL Enables the PID function for direct acting systems. An increase in the feedback variable will cause a decrease in motor speed. REVERSE Enables the PID function for reverse acting systems. An increase in the feedback variable will cause an increase in motor speed. NOTE: The REVERSE selection is not used to compensate for reverse acting feedback devices. If a reverse acting feedback device is used, program Parameters 75 and 76 - FB @ MIN and FB @ MAX as described in Section 19.1 - FEEDBACK DEVICES.
75 FB @ MIN (MINIMUM FEEDBACK VALUE) This parameter should be set to the value of the process variable that corresponds to the minimum transducer feedback signal (0 VDC or 4 mA). 76 FB @ MAX (MAXIMUM FEEDBACK VALUE) This parameter should be set to the value of the process variable that corresponds to the maximum transducer feedback signal (10 VDC or 20 mA).
NOTE: Differential gain is used as a “shock-absorber” to dampen overshoots in fast-acting systems. However, it can be very sensitive to “noise” on the feedback signal and to digitizing errors, so it must be used with caution. 80 PID ACC (PID ACCEL/DECEL) This parameter sets the acceleration and deceleration rate of the setpoint reference into the PID unit.
98 LANGUAGE (LANGUAGE SELECTION) The AC400 Series drive can support other languages with the addition of an optional LANGUAGE EEPROM chip installed in socket U11 on the control board of the drive. If the EEPROM is not present, the default language will be ENGLISH. Also, this parameter is not affected when the parameters are reset using Parameter 65 - PROGRAM. Therefore, if a language other than ENGLISH is selected, it will remain in effect after a RESET.
19.0 AC400 PID SETPOINT CONTROL PID Setpoint Control allows the AC400 to maintain a process setpoint, such as PSI or CFM, without using an external controller. When PID is activated, the AC400 will operate in a closed-loop fashion, automatically adjusting the motor speed to maintain the setpoint. PID setpoint control requires feedback from the process in order to compare the process variable “value” to the setpoint. The difference between the process variable “value” and the setpoint is called the error.
Feedback devices can be direct or reverse acting. A direct acting device outputs a signal that increases as the process variable increases. A reverse acting device outputs a signal that decreases as the process variable increases. The programming of Parameters 75 - FB @ MIN and 76 - FB @ MAX depend on the type of feedback device being used.
19.3 PID CONTROL - DIRECT AND REVERSE ACTING The PID Setpoint Control software can be direct or reverse acting, and must be set to match the system. This is accomplished with Parameter 70 - PID MODE. When set to NORMAL (for direct acting systems), the PID unit will command an increase in motor speed if the process variable feedback decreases, and a decrease in motor speed if the process variable feedback increases. When set to REVERSE (for reverse acting systems), the opposite is true.
Remote setpoint reference inputs at TB-5A and TB-5B can only be used if that terminal is NOT being used for the process feedback signal from a transducer. The AC400 has only one analog input of each type, so the same type of signal cannot be used for transducer feedback and setpoint reference. For example, a 4-20 mA signal from a transducer could not be used as a feedback signal if the setpoint is being controlled by a 4-20 mA signal from a PLC. 19.
19.6 AC400 DISPLAY IN PID MODE When the drive is in PID mode, the DRIVE STATUS portion of the display will indicate actual output frequency (in Hertz) instead of RUN, and the right side of the display will indicate PID SETPOINT, % LOAD, or PID FEEDBACK. The ENTER key is used to toggle between the different displays. Examples of the possible displays are shown below: In the examples above, the drive is running at 42.53 Hz to maintain the PID SETPOINT of 35.0 psi.
20.0 TROUBLESHOOTING The table below lists the fault conditions that will cause the drive to shut down, as well as some possible causes. Please contact the factory for more information on troubleshooting faults. NOTE: The drive will not automatically restart after a PWR SAG or a CONTROL fault. Also, if an OUTPUT fault occurs below 1.5 Hz, the drive will only attempt one restart, after a four minute delay. If unsuccessful, it will then trip into FAULT LOCKOUT, which will require a manual reset.
FAULT MESSAGES FAULT DESCRIPTION POSSIBLE CAUSES EXTERNAL External fault: TB-13D is open or closed to TB-2, depending on setting of Parameter 50 - TB13D. Check setting of Parameter 50. Check devices wired between TB13D and TB-2. DB ERROR Dynamic Brake fault: DB circuit has sensed a resistor overload. The DB duty cycle is too high, causing the resistors to overheat. CONTROL Control Board fault: New software has been installed that is different from the previous version.
21.0 USER SETTING RECORD PARAMETER MENU: USER SETTING RECORD PARAM. NUMBER PARAMETER NAME FACTORY DEFAULT 0 LINE VOLTS AUTO 1 SPEED #1 20.00 Hz 2 SPEED #2 20.00 Hz 3 SPEED #3 20.00 Hz 4 SPEED #4 20.00 Hz 5 SKIP #1 .00 Hz 6 SKIP #2 .00 Hz 7 BAND WID 1.00 Hz 8 ACCEL 30.0 SEC 9 DECEL 30.0 SEC 10 MIN FRQ .50 Hz 11 MAX FRQ 60.00 Hz 12 DC BRAKE .0 VDC 13 DC TIME .0 SEC 14 DYN BRAKE OFF 16 CURRENT 180 % 17 MOTOR OL 100% 18 BASE 60.
PARAMETER MENU: USER SETTING RECORD PARAM. NUMBER PARAMETER NAME FACTORY DEFAULT 35 CONTRAST HIGH 39 TB5 MIN .00 Hz 40 TB5 MAX 60.00 Hz 42 TB10A OUT NONE 43 @TB10A 60.
PARAMETER MENU: USER SETTING RECORD PARAM. NUMBER PARAMETER NAME FACTORY DEFAULT 80 PID ACC 30.0 SEC 81 MIN ALRM 0.0% 82 MAX ALRM 0.
Notes
Minarik Corporation 901 E. Thompson Avenue, Glendale CA 91201-2011 Sales: 800-646-2745, FAX: 800-394-6334 www.minarikcorp.com Document Number: 250-0303, Rev. 0 Printed in the U.S.A – 11/00 U.S.A. $10.00, Outside U.S.A. $11.
